Construction and coating materials



a, Unlted States Patent CONSTRUCTION AND COATING MATERIALS GlennSucetti, Grass Valley, Calif.

No Drawing. Application July 31, 1956 Serial No. 601,114

16 Claims. (Cl. 106277) This invention relates to plastic constructionmaterials and to plastic coating and overlayment materials in which thebodying material or filler is a mineral aggregate and the bonding agentis Portland cement or the like.

This application is a continuation-in-part of my copending applicationSerial No. 422,994, filed April 13, 1954, entitled overlayment Material,hereinafter referred to as the parent application.

In my parent application there is described and claimed a plasticproduct comprising an aggregate treated with calcium chloride solutionand then with a stabilized, mixing type bitum' ion. The aggregate mayvary from an aggregate consisting entirely of porous mineral articles(e. g., expanded vermiculite, expande per rte, Hay rte, scoria, ppmiceo'r the lik) to a mixture predominating in a dense, nonporous aggregatesuch as sand or gravel mixed with a small amount, e. g., of porousaggregate. The bituminous emulsion is preferably an asphalt emulsionprepared in accordance with Buckley U. S. Patent No. 2,256,886, thestabilizing agent being Vinsol Resin. Further identification of VinsolResin will be found in the said parent application, in the said Buckleypatent and in Maters U. S. Patents Nos. 2,199,206 and 2,155,141. Verybriefly, Vinsol Resin is a. saponified petroleum insoluble, solventextracted pine wood resin which is characterized by freedom from woodrosin, solubility in alcohol, a methoxy content of about 3 to 6%, anacid number of about 100 and a melting point of about 125 C.

The present invention relates to improvements upon the invention of myparent application. More particularly the present invention relates tothe production of treated aggregates which can be easily introduced intobags; which can be stored, shipped and handled in bags of the typeconsisting of outer plies of paper and an interior ply of polyethylenefilm without water damage to the bags; which can be poured easily fromthe bags when desired and can be easily mixed with water and Portlandcem t; and which. when mixed with water and Portland cement, willproduce a concrete which is excellent for overlayment purposes.

In one embodiment the invention comprises a composition of matterconsisting essentially of a moist intimate admixture of a major portionof dense concrete aggregate particles such as sand, gravel, Haydite,etc., having an apparent density of about 50 pounds per cubic foot orhigher and a minor portion of about 5% to about by volume of the totalaggregate particles of low density concrete aggregate particles havingan apparent density of less than about twenty pounds per cubic foot, atleast said dense particles bearing a first coating-film of an aqueoussolution of a salt selected from the groupconsisting of hygroscopiccalcium salts and hygroscopic magnesium salts which has been added, forexample, in an amount of about 2 to about 4 gallons of an aqueoussolution (preferably about 1% to about 3% salt concentration) per cubicfoot of aggregate; and an overlying deposit of an oil-in-watermixing-type bituminous emulsion, for exit LT Patented Nov. 18, 1958ample, of 45-55% asphalt content added in an amount of about 0.5 toabout 1.5 gallons per cubic foot of aggregate, said dense and said lightweight aggregatees being of a size range normally employed with cementbinders and water to form mortar, the composition being furthercharacterized in that it is sufliciently free-flowing to be poured fromcontainers and readily mixed with water and a hydraulic cement binder toform a mortar which is readily poured, screeded and troweled withoutundue loss of volume or segregation of components before setting to forma rigid structure.

In a further embodiment the invention comprises the method of preparinga premixed aggregate suitable for mixing with hydraulic cement and waterto form mortar which is readily poured, screeded and troweled withoutundue loss of volume or segregation of components before it sets, whichcomprises; mixing an aggregate of a particle size commonly employed withhydraulic cements with a dilute aqueous solution of a salt selected fromthe group consisting of the hygroscopic salts of calcium and magncsium,sufficient to moisten the aggregate and deposit a uniform coating ofsaid salt on the aggregate particles, then mixing the thus coatedparticles with a mixing-type bituminous emulsion of the oil-in-watertype to coat the surfaces of the particles to form a moist, plastic,pourable mass containing no free water as a separate phase.

There 'exists a need, which has been met in rather unsatisfactorymanner, for what I call an overlayment concrete. By this I mean amaterial containing mineral aggregate as the structural component andPortland cement (or other suitable hydraulic cement) as the bondingagent; such material being capable of application to solid structuralsurfaces such as structural concrete. Typical uses of such overlaymentconcrete are to repair damaged structural concrete, to coat structuralconcrete and other like solid structural surfaces with a protective orwearing coat, e. g., to sustain foot and vehicular traffic; and toprovide tapered, feathered edges. For example, in a city the needfrequently arises to repair worn, gouged or broken sidewalks, tenniscourts and other concrete areas. Also, it may be desirable to provide awearing surface for a structural concrete floor, such wearing surfacehaving insulating properties as well as wearing qualities. And it may bedesirable, e. g., in repair jobs, to taper or feather the concrete usedfor repair purposes so that the new concrete is flush with, or tapersdown to the surface of the old concrete.

It will be understood that, in such instances, certain problems anddesiderata exist which do not exist or are of lesser importance in theinitial operation of laying down a thick, structural concrete floor,sidewalk or the like. The size of initial installations, the thicknessof the concrete installed and other factors solve or minimize problemswhch are of a major nature in smaller operations such as repair jobs.

Thus, it is desirable to supply the property owner or contractor doing asmall repair job, with a bagged aggregate which he can then mix inproper proportions with water and Portland cement; e. g., 5 bags ofaggregate and one bag of Portland cement. From the standpoint of thesupplier, the bags should be easy to fill; i. e., expensive hand laborin filling should be eliminated, otherwise the filling operation mayoverprice the bagged aggregate. From the standpoint of all concerned,the bagged aggregate should be easy to handle; it must store and shipwithout damage or deterioration other than that occasioned by accidentor careless handling; and it must remain in properly usable state, i.e., undeteriorated and easily pourable when required.

It is an object of the present invention to provide such a material, i.e., a treated aggregate which can be bagged easily and which fulfillsthe conditions stated above.

It is a further object of the invention to provide a treated aggregiateof this character and a method whereby it can be mixed with water andPortland cement or the like to produce a concrete mix which is efficientfor repair purposes and, more generally, as an excellent overlaymentmaterial which will bond well to an underlying, thick structuralmaterial such as structural concrete and will provide a durableprotective layer.

These and other objects of the present invention will be apparent fromthe ensuing description and the appended claims.

In accordance with the invention of my parent application, I employ arelatively dense aggregate and a lightweight, porous aggregate inadmixture, and I treat the aggregate mixture with both aqueous calciumchloride solution and a stable mixing type bituminous emulsion. However,in the present invention I vary the procedure of my parent applicationin several important respects, as explained below.

The aggregate, as stated, is a mixture of dense and light aggregates.The dense aggregate may be sand and/or gravel; or it may be a syntheticaggregate such as Haydite; or it may be a mixture of such aggregates.(Haydite is a burnt clay aggregate, preferably having a density of about60 pounds per cubic foot. It is considered a lightweight aggregatecompared to sand and gravel weighing about 90 pounds per cubic foot, butit may be considered a dense aggregate for purposes of my presentinvention. The method of making it is described in Hayde Patent1,707,395).

The lightweight, porous aggregate is preferably expanded xenmiu lite orwi iiitetlweighing about 8-10 pounds per cubic foot, but ot er 1gtweight, porous aggregates may be used such aw Generally, the denseaggregate s ould have a density not less than about 50 pounds,preferably not less than about 60 pounds per cubic foot; and the lightaggregate should have a density not more than about 20 pounds,preferably not more than about 12 pounds per cubic foot.

The dense and lightweight aggregates may be premixed and then treated inaccordance with my present invention, but preferably they are addedseparately and in the order indicated hereinafter. In either case, i.e., premixing or stagewise addition, the dense aggregate predominates inamount, generally being about 90% of the volume of aggregate butpermissibly varying from 80% or less to 95% or slightly more. Thus thevolume proportion of lightweight aggregate based on total aggregatevolume is preferably 5 to 20%, and is most advantageously about 10%.

In treating the aggregate in accordance with the present invention Iemploy a suitable mixer such as a paddle mixer operating at about 50 R.P. M.; I first add to the mixer water containing dissolved hygroscopicsalt of calcium or magnesium such as calcium chloride and magnesiumchloride and preferably calcium chloride; I may then add the entireaggregate (e. g., a 90-10 by volume mixture of sand or Haydite, and No.4 expanded vermiculite), but I prefer at this stage to add only thedense aggregate; and I then add a specially prepared asphalt emulsionwhich is described hereinafter. If, in accordance with the preferredprocedure, only dense aggregate has been added at this stage, I then addlightweight aggregate. Meanwhile the mixer will be operating and itsoperation will be continued after the last addition of ingredients untila homogeneous, plastic mass is produced.

I have found that by this means, and especially if the preferredprocedure is followed, a plastic, treated aggregate is produced whichhas the following very useful properties: The water and emulsion renderthe aggregate desirably plastic, whereby bags can be readily filled, e.g., by feeding the aggregate through a 6 inch helical feed screw into athree inch spout, thence into the bags. By this means, the fillingoperation is speeded and is much more economical. This desirable plasticproperty, and other useful properties to he described hereinafter, aremore fully developed if the treated aggregate is held for a period oftime, c. g., 15 to 30 minutes, in a hopper. It appears that during thisholding period, the water in the mixture is absorbed by the porousaggregate and air is displaced from the pores and voids of the porousaggregate and becomes entrapped in the mix in the form of bubbles. Themixture therefore becomes plastic by reason of air bubbles which enablethe mix to flow easily into bags yet the plastic flowing properties donot have an adverse effect on bags as there is little or no free waterpresent as a separate liquid phase.

The bagged mixture has a desirable firmness which is highly advantageousbecause it facilitates handling as compared to an overly plastic orliquid product. This firmness enables bags to be piled ten high withoutrupture. Also, in the case of bag failure, the product does not squirtand run out. A150, and quite importantly, by reason of the fact that thewater is locked up in the pores of the lightweight aggregate, paper bagsmay be employed of the type mentioned, i. e., outer surface plies ofpaper and an interior ply of a polyethylene liner which forms a barrierto water vapor. If a highly aqueous aggregate w e used, it would have adamaging effect on such bags and would require metal containers.

Moreover when received by the user and opened, the bags will pour theircontents easily and can be mixed easily with water and Portland cement,even after long storage and/or shipment.

As a concluding step in the procedure of my invention it may be pointedout that the mixing procedure viewed in its entirety is unorthodox andthat such deviation from customary procedure has certain advantages.Thus, it is customary to prepare a concrete mix by first adding Portlandcement to water, then adding the aggregate. In my procefure theaggregate is added first and the cement afterwards, preferably after allthe water has been added.

This concluding step in the procedure of my inventionthe step of addingcement last-has the advantage of producing a much more plastic, easilyworked mix in which the components are much less lilzely to segregate. Iattribute these advantages to the displacement of air from the cementparticles and its entrapment in the mix in the form of bubbles which arestabilized by the stabilizer which is present in the emulsion.

To recapitulate my invention in its entirety: (l) I employ a mixture ofaggregate, such mixture predominating in dense aggregate such as sand,gravel and/or Haydite and containing a small but substantial amount, e.g.. 10% by volume of lightweight porous aggregate such as expandedvermiculite or expanded perlite. (2) l preferably add the denseaggregate to water which contains sufiicient calcium chloride inaccordance with the teachings of my parent application. (3) I then add astabilized, mixing type bituminous emulsion, preferably stabilized bymore than 2% by weight of saponified Vinsol Resin and preferablycontaining a greater amount of saponified Vinsol Resin than presentlyavailable commercial emulsions, as described in more detail hereinafter.This enriched emulsion is added in quantities as taught in my parentapplication. (4) I then add the lightweight aggregate. Meanwhile theingredients are mixed and mixing is continued until a homogeneous,plastic mass is produced. (5) Then the mix is held for a period of time,usually 15 to 30 minutes, for the water to be thoroughly taken up by thelightweight aggregate. (6) Then paper bags having an interior lining,membrane or vapor barrier of plastic such as a polyethylene, are filledwith the plastic mix and are sealed. This filling operation may becarried out by continuous means such as a simple screw feed and a smallspout. (7) The bags may be stored and shipped without damage ordeterioration other than that occasioned by severe accidents or verycareless handling. (8) When used, the bags are opened, the contents arepoured into a concrete mixer, water is added and then cement, all in theproper proportions.

Turning now to the calcium chloride solution, the latter is preferablyabout 1 to 3% concentration although higher and lower concentrations maybe employed. The quantity of solution may vary from 2 to 4 gallons, moreor less, per cubic foot of aggregate. The amount of the salt is about0.5 pound to about 4 pounds per 5 cubic feet of aggregate. Too great aquantity of solution will render the product too mushy" or fluid and toolittle will render it too stiff and diflicult to flow and will notaccomplish the desired end results.

The bituminous emulsion may be an asphalt emulsion or other bituminousemulsion of the oil-in-water type, preferably containing about 45 to 55%asphalt, which is stabilized to give a mixing type emulsion, e. g.,passing ASTM D3146 mixing test. This test is now identified as ASTMD977-57. It is used to test emulsions of Type SS-l which are defined asslow setting asphalt emulsions for fine aggregate mixes in which asubstantial quantity of aggregate passes a 4; inch sieve and a portionmay pass a No. 200 (74 micron) sieve. Thus, the stable mixing typeemulsions are those which can be mixed with fine aggregate withoutbreaking. The emulsion is preferably employed in the amount of about onegallon per cubic foot of aggregate, although the amount of emulsion mayvary from about /2 to 1% gallons, more or less, per cubic foot ofaggregate. Preferably the emulsion is stabilized by saponified VinsolResin (hereinafter referred to simply as Vinsol Resin). Presentlyavailable commercial emulsions contain about 2% by weight of VinsolResin. 1 have found that superior results are obtained if the emulsionis enriched in Vinsol Resin, to contain not less than about 2.5%. Thus,with these enriched emulsions, there is much less tendency for the heavyaggregate particles to separate in the bagged mix, and for the aggregateand cement particles to separate in the final concrete mix and in theend product (cured concrete overlayment).

The following specific examples will serve further to illustrate thepractice and advantages of the invention:

Example 1.8 gallons of water containing 5 pounds calcium chloride per 50gallons (about 1.2% CaCl were placed in a mixer followed by 4 cubic feetof sand, 4 gallons of asphalt emulsion containing about 55% of asphaltstabilized by about 2.4% of saponified Vinsol Resin and lo cublic footof No. 4 expanded vermiculite. These ingredients were added in the order0 a plaster mixer while operating at 40 R. P. M. This order of mixinghad the following beneficial results: It diminished considerably theamount of breakdown of the vermiculite particles; a larger proportion ofair in the voids of the aggregate was displaced and entrapped in the mixin the form of bubbles which were stabilized by the asphalt emulsion;and the mix had a very desirable plasticity and exhibited littletendency for the sand to settle. Thus the mix could be poured easilythrough a four inch spout and after being transported 600 miles it wasstill in excellent condition without any noticeable separation of sand.The water was taken up to such an extent by the vermiculite that the mixcould be stored and shipped in waterproof bags, yet retain a desirablefirmness.

At the end of the 600 mile trip, above-mentioned, Portland cement wasadded in the proportion of about one bag per 4 cubic feet of aggregate.Water was also added to produce the desired consistency. The concretemix so produced was employed to overlay sidewalks at a motel. A season'suse has indicated excellent result.

Other advantages of the mixing procedure described 6 above are thefollowing: The wet mix screeds and trowels better; little or no waterdrop out occurs; concrete prepared from these mixes has greaterstrength; equal slump values are obtainable with 10% less water.

Example 2.Minus 8 mesh dry Haydite was employed as the dense aggregate.This aggregate weighs about 59 pounds per cubic foot. Two cubic feet ofthis Haydite were added with mixing to 3%. gallons of aqueous calciumchloride solution containing /2 pound (1.8%) calcium chloride. Then 2gallons of the same asphalt emulsion as used in Example 1 were added.Meanwhile mixing was carried out. A very stiff mix resulted which hungto the paddles of the mixer and would not run off like a free-flowingmix. Then 2 pounds cubic foot) of No. 4 expanded vermiculite was added,while mixing continued. At first the mix appeared to go completely dryand to lose its plasticity, but within one minute air bubbles formed socompletely throughout the mass that it would run freely from the paddlesof the mixer and flowed easily into a bag.

Two bags of one cubic foot capacity each were filled with this mix, andwere sealed. Each weighed pounds. At first the bags were quite soft butthe next day they were desirably firm. Apparently during this short timeinterval the vermiculite and Haydite took up enough of the free water tocause the mass to firm uP'! The procedure set forth in Example 2 has thefollowing advantages, among others: It gives a greater yield, i. e., agreater volume of end product. Also, it employs less water, e. g., 10%less water than my prior procedure when the vermiculite is added firstrather than last. Less water means that the mix can be stored moresafely in multiple wall paper bags having a polyethylene liner. Also,less water means less freight charges.

The No. 4 vermiculite referred to above has a screen analysis asfollows:

and novel products have been provided whereby an overlayment type ofconcrete is readily and economically available to large and small usersalike, in a form which is easy to employ and which yields a very highquality end product. The overlayment concrete of the invention may beemployed not only for overlayment of structural concrete but also foroverlayment of vermiculite concrete and over firm ground, asphalticconcrete, etc.

I claim:

1. A composition of matter consisting essentially of a moist intimateadmixture of a major portion of dense concrete aggregate particleshaving an apparent density of above about fifty pounds per cubic footand a minor portion of about 5% to about 20% by volume of the totalaggregate of a low density concrete aggregate having an apparent densityof less than about twenty pounds per cubic foot, at least said denseparticles bearing a first coating-film of an aqueous solution of a saltselected from the group consisting of hygroscopic calcium salts andhygroscopic magnesium salts, and an overlying de posit of anoil-in-water stable mixing-type bituminous emulsion such as that passingASTM D631-46 mixing test, said dense and said light weight aggregatesbeing of a size range normally employed with hydraulic binders and waterto form mortar, said composition being further characterized in that itis an essentially particulate aggregate which is sufficientlyfree-flowing to be poured from containers and readily mixed with waterand a hydraulic cement binder to form a mortar which is readily poured,screeded and troweled without undue loss of volume or segregation ofcomponents before setting to form a rigid structure.

2. The composition of claim 1 wherein the hygroscopic salt is calciumchloride.

3. The composition of claim 1 wherein the proportions of hygroscopicsalt in the first film are about 0.5 to about 4 pounds per cubic feet ofaggregate.

4. The composition of claim 1 wherein the low density aggregate isexpanded vermiculite.

5. The composition of claim 1 wherein the low density aggregate isexpanded perlite.

6. The composition of claim 1 wherein the dense aggregate is sand.

7. The composition of claim 1 wherein the dense aggregate is Haydite.

8. The composition of claim 1 wherein the asphalt emulsion is stabilizedby more than 2% of a saponitied petroleum insoluble, solvent extractpinewood resin, which is characterized by freedom from wood rosin,solubility in alcohol, a methoxy content of 36%, an acid number of about100 and a melting point of about 125 C.

9. The method of preparing a premixed aggregate suitable for mixing withhydraulic cement and water to form mortar which is readily poured,screeded and troweled without undue loss of volume or segregation ofcomponents before it sets, which comprises; providing a mixture of amajor proportion of a dense concrete aggregate having an apparentdensity of at least about 5 poun 5 per cubic foot, a minor proportion ofabout 5 to about 20% by volume of the total aggregate, of a low densitconcrete a egate having an apparent denmle s s than about 2mer'enbicronfififi aggregates having a particle size commonly employedwith hydraulic cements mixing said mixed aggregates with a diluteaqueous solution of a salt selected from the group consisting of thehygroscopic salts of calcium and magnesium, sufiicient to moisten theaggregate and deposit a uniform coating of said salt on the aggregateparticles, then mixing the thus coated particles with a stablemixing-type bituminous emulsion of the oil-inwater type passing ASTMD631-46 mixing test, to completely coat the surfaces of the particles toform a plastic, esesntially particulate pourable aggregate mass.

10. The method of preparing a pre-mixed aggregate suitable for mixingwith hydraulic cement binder and water which comprises; mixing denseconcrete aggregate particles having an apparent density of at leastabout 50 pounds per cubic foot, with a dilute aqueous solution of a saltselected from the group consisting of hygroscopic calcium salts andhygroscopic magnesium salts to moisten the particles of said aggregate,adding and mixing therewith an oil-in-water stable mixing-typebituminous emulsion passing ASTM D63l-46 mixing test to deposit a filmof said emulsion on said moist particles, adding and mixing therewith aminor portion of about 5% to about 20% by volume of the total aggregate,of low density concrete aggregate particles having an apparent densityof less than about 20 pounds per cubic foot and recovering a moistcomposition which is an essentially particulate aggregate and issufiiciently free-flowing to be poured from a container and be readilymixed with water and a hydraulic cement binder to form mortar which isreadily poured, screeded and troweled without undue loss of volume orsegregation of components before it sets.

11. The method of claim 10 wherein the proportions of said salt is about0.5 to about 4 pounds per 5 cubic feet of total aggregate, and theasphalt emulsion contains about 45% to about 55% asphalt and is added inthe amount of about 0.5 to about 1.5 gallons per cubic foot of totalaggregate.

12. The method of claim 10 wherein the asphalt emulsion is stabilized bymore than 2.0% of a saponified petroleum insoluble, solvent extractedpinewood resin which is characterized by freedom from wood rosin,solubility in alcohol, a methoxy content of 36%, an acid number of aboutand a melting point of about C.

13. The process of claim 10 wherein the salt is calcium chloride.

14. The method of preparing a pre-mixed aggregate suitable for mixingwith hydraulic cement and water to form mortar which comprises; mixingdense aggregate particles having an apparent density of at least about50 pounds per cubic foot, and low density concrete aggregate particleshaving an apparent density of less than about 20 pounds per cubic foot,said aggregates being of a particle size commonly employed withhydraulic cement binders, with about 2 to 4 gallons per cubic foot ofaggregate, of an aqueous solution of a salt selected from the groupconsisting of calcium chloride and magnesium chloride in an amountequivalent to about 0.5 to about 4 pounds of salt per 5 cubic feet ofaggregate, to moisten the aggregate, mixing the moist aggregate with anoil-in-water stable mixing-type bituminous emulsion passing ASTM D63l-46 mixing test, said emulsion containing about 45% to about 55%asphalt in an amount of about 0.5 to about 1.5 gallons of emulsion percubic foot of aggregate to form a uniform mixture, and recovering theresultant aggregate composition characterized by being an essentiallyparticulate aggregate and is sufficiently free-flowing to be poured fromcontainers and readily mixed with water and a hydraulic cement binder toform mortar which is readily poured, screeded and troweled without undueloss of volume and undue segregation of components before setting toform a rigid structure.

15. The process of claim 14 wherein the asphalt emulsion is stabilizedby a saponified petroleum insoluble, solvent extracted pinewood resinwhich is characterized by freedom from wood rosin, solubility inalcohol, a methoxy content of 36%, an acid number of about 100 and amelting point of about 125 C.

16. The process of claim 14 wherein the salt is calcium chloride.

References Cited in the file of this patent UNITED STATES PATENTS1,563,755 Leonardt Dec. 1, 1925 2,074,758 Reynolds Mar. 23, 19372,335,978 Vogt Dec. 7, 1943 2,355,966 Goflf Aug. 15, 1944 2,376,447Mullin May 22, 1945 2,377,491 Goodrich et al. June 5, 1945 2,399,411Watts et al. Apr. 30, 1946 2,468,533 Worson Apr. 26, 1949 2,483,806Buckley et al. Oct. 4, 1949 2,483,835 Manzer Oct. 4, 1949 2,677,165Copenhaver May 4, 1954

1. A COMPOSITION OF MATTER CONSISTING ESSENTIALLY OF A MOIST INTIMATEADMIXTURE OF A MAJOR PORTION OF DENSE CONCRETE AGGREGATE PARTICLESHAVING AN APPARENT DENSITY OF ABOVE ABOUT FIFTY POUNDS PER CUBIC FOOTAND A MINOR PORTION OF ABOUT 5% TO ABOUT 20% BY VOLUME OF THE TOTALAGGREGATE OF A LOW DENSITY CONCRETE AGGREGATE HAVING AN APPARENT DENSITYOF LESS THAN ABOUT TWENTY POUNDS PER CUBIC FOOT, AT LEAST SAID DENSEPARTICLES BEARING A FIRST COATING-FILM OF AN AQUEOUS SOLUTION OF A SALTSELECTED FROM THE GROUP CONSISTING OF HYGROSCOPIC CALCIUM SALTS ANDHYGROSCOPIC MAGNESIUM SALTS, AND AN OVERLYING DEPOSIT OF AN OIL-IN-WATERSTABLE MIXING-TYPE BITUMINOUS EMULSION SUCH AS THAT PASSING ASTM D631-46MIXING TEST, SAID DENSE AND SAID LIGHT WEIGHT AGGREGATES BEING OF A SIZERANGE NORMALLY EMPLOYED WITH HYDRAULIC BINDERS AND WATER TO FORM MORTAR,SAID COMPOSITION BEING FURTHER CHARACTERIZED IN THAT IT IS ANESSENTIALLY PARTICULATE AGGREGATE WHICH IS SUFFICIENTLY FREE-FLOWING TOBE POURED FROM CONTAINERS AND READILY MIXED WITH WATER AND A HYDRAULICCEMENT BINDER TO FORM A MORTAR WHICH IS READILY POURED, SCREEDED ANDTROWELED WITHOUT UNDUE LOSS OF VOLUME OR SEGREGATION OF COMPONENTSBEFORE SETTING TO FORM A RIGID STRUCTURE.